Method for molding a trim panel with integrally formed simulated leather appliques

ABSTRACT

An instrument trim panel (12) includes a shell (14) made from a flexible plastic material. A textured section (18) is circumscribed by a simulated seam (20). A closed cell plastic block (28) is press fitted behind the textured section. An air pocket (26) is interposed between the block and textured section. A rigid substrate (22) is molded and cured behind the shell (14) and block (28). The air pocket allows the textured section to be deformed to simulate the appearance and feel of a leather applique.

TECHNICAL FIELD

The field of this invention relates to a motor vehicular interior trimpanel having simulated leather appliques.

BACKGROUND OF THE DISCLOSURE

The use of thin walled plastic shells for products have included a castshell of thermoplastic material with a decorative texture formedtherein. The thin walled plastic shell is bonded to an underlyingsupportive substrate of rigidly cured plastic foam. Foam backed thinwall plastic shells have seen wide commercial utilization in interiortrim panels for motor vehicles.

In order to promote the appearance of rich and luxurious interior,simulated leather appliques or folded leather have been adhered onto thetrim panel. Often, the applique is formed by wrapping leather orsimulated leather over a cushion foam section and substrate and bondingthe leather to the backside of the substrate in such a way as to formwrinkles or folds in the leather that is on the front surface of thecushion foam. The applique is then adhered to the trim panel.

The cost and weight of these appliques are both high. The weight isgreater due to the redundant substrate material for both the appliqueand the trim panel. Production of a separate applique that issubsequently attached to the trim panel is also expensive due to theadditional tooling and steps required to form the applique and tosubsequently adhere it to the trim panel.

What is needed is a trim panel with a simulated folded leather appliqueappearance. Furthermore, what is needed is a method of manufacturing atrim panel that incorporates a simulated leather applique having atextured surface.

SUMMARY OF THE DISCLOSURE

In accordance with one aspect of the invention, a method of integrallymolding a trim panel for a motor vehicle and the like includes forming asimulated leather applique integral with the panel. The method includesthe first step of forming a thin plastic outer shell having a backsidesurface and front outer surface. The thin plastic shell is positioned ina mold having a standing knife edge that circumscribes a texturedsection of the mold to form a textured section on the front surface ofthe shell. A closed cell non-porous cushion foam block is positioned atthe backside surface of the shell opposite the textured section. Theside walls of said cushion foam block are press fitted against uprightwalls of the shell that abut the standing knife edge.

A curable substrate is molded on a backside surface of the cushion foamand the backside surface of the plastic shell about the textured sectionsuch that upon curing, the substrate provides rigid support. A trimpanel is thus formed with the substrate, cushion foam block, and plasticshell with a simulated applique located in front of said cushion foamblock. After the mold with the knife edge is removed, a simulated seamis formed about the textured section.

Preferably, a compressible material is trapped between the cushion foamblock and the textured section of the shell during the placement of saidcushion foam block to allow deformation of the textured section upon anapplication of a small force after the substrate is cured. The materialmay be a low density open or closed cell foam or even merely a pocket ofair.

In accordance with another aspect of the invention, a trim panelincludes a shell of flexible plastic material that has a front exposedsurface and a back surface. The front exposed surface has a texturedsection desirably simulating a plurality of wrinkles. A rigid curedsubstrate is adhered to a back surface of the shell about the texturedsection. A cushion member is interposed between the back side at thetextured section of the shell and the rigid cured substrate.

The trim panel preferably has an upright wall with an upright doublelayered wall with a seam therebetween. The wall surrounds the cushionmember such that a seam appears from the front exposed surface of theshell circumscribing the texture section. The trim panel preferably hasits cushion member being press fitted against said texture sectionbetween opposing sections of said wall.

A compressible material such as a pocket of air is trapped between thecushion member and the texture section of the shell. The texturedsection preferably looks like folded or wrinkled leather that is appliedonto the remainder of the trim panel. The textured section has the feelof genuine leather by being easily deformed against the air pocket whena small force is applied onto the textured section.

BRIEF DESCRIPTION OF THE DRAWINGS

Reference now is made to the accompanying drawings in which:

FIG. 1 is a perspective view of an interior of a motor vehicleillustrating an instrument panel and other trim panels in accordancewith one embodiment of the invention;

FIG. 2 is a cross-sectional view taken along lines 2--2 shown in FIG. 1;

FIG. 3 is a fragmentary view illustrating a step in the method used tofabricate the construction shown in FIGS. 1 and 2;

FIG. 4 is a view similar to FIG. 3 illustrating a subsequent step ofpressing the cushion foam block in place; and

FIG. 5 is a view similar to FIG. 4 illustrating a subsequent step ofproviding a substrate of curable rigid urethane to form the illustratedembodiment.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to FIGS. 1 and 2, an interior 10 of a motor vehicle isshown with an interior trim component representatively shown as aninstrument panel 12 and other trim panels 13. The panels 12 and 13 moreparticularly include an outer shell 14 that includes an outwardly facingexposed front surface 16. Further reference is made only to instrumentpanel 12 with the understanding that the same structure and method canbe applied to trim panel 13. The front surface 16 includes at least onesimulated leather applique section 18. A simulated seam 20 surrounds thesimulated applique section 18.

The outer shell 14 is made from a relatively soft polyvinyl chlorideresin material (PVC). As shown in more detail in FIG. 2, the outer shell16 has its backside surface 24 bonded to a rigid foam material 22 exceptat its textured applique section 18.

A closed cell cushion block 28 is positioned behind the backside surface25 at the applique section 18. The seam 20 is formed by a double layeredupstanding wall section 30 having layers 31 and 32 folded at distalridge 33. The cushion member abuts layer 31 while the rigid foam 22abuts layer 32. An air pocket 26 is interposed between the closed cellcushion block 28 and textured applique section 18. The back surface 46of the block 28 is aligned with the distal ridge 33 of wall section 30.

The textured applique section 18 has a plurality of folds or wrinkles 35in the front surface 17 to simulate leather. The air pocket 26 behindthe texture section 18 allows the textured section to be easilydeformable against a small force to simulate the feel of a leatherapplique.

The texture section 18 has its outer surface 17 even with respect to thefront surface 16 of the section about the textured section 18. It shouldbe understood that the surface 17 may also be raised or recessed withrespect to surface 16. Furthermore, the surfaces 16 and 17 need not beplanar, but may be formed with a contour.

Formation of the instrument panel 10 starts with formation of the shell14. The shell 14 may be formed in a shell mold typical to the castprocess or produced in a pour mold typical to the spray urethane orvacuum forming process. As shown in FIG. 3, a pour mold 40 is shownhaving an upstanding knife edge 42 positioned about the periphery of thetextured section 18. A sheet of pliable PVC is placed in the mold and isvacuum molded into the appropriate shaped shell 14 forming the texturedsections 18 and front surfaces 16 and 17.

As shown in FIG. 4, the cushion member 28 is press fitted behind thetextured section 18 with its side walls 44 pressed against opposinglayers 31 of upstanding wall section 30. The press fit of cushion member28 forms the air pocket 26 between the textured section 18 and thecushion member 28. The press fit of the block 28 within upstanding wallsection 30 seals the pocket 26 against leakage.

The substrate backing 22 of urethane foam is then molded onto the backsurface 24 of the shell 14, the wall layer 32 and the back surface 46 ofcushion block 28. The pourable uncured urethane does not leak betweenthe layer 31 and the cushion block 28 due to the press fit of block 28.The closed cell nature of the cushion block 28 also prevents theurethane foam from penetrating therethrough and into air pocket 26. Oncecured the foam forms a rigid substrate 22 which provides structuralrigidity to the entire instrument panel 12. The panels 12 are thendemolded from mold 40.

Once the panel 12 is demolded, the air pocket 26 remains between thetextured section 18 of the shell 14 and the cushion member 28.Consequently, the PVC shell material at the texture section 18 remainseasily deformable when a small amount of force is applied to itresulting in a simulated feel of leather which is deformable andflexible.

Furthermore, the demolding of layers 31 and 32 from the knife edgesections 42 of the mold 40 form the seams 20 which simulate theappearance of a separate leather applique adhered onto the instrumentpanel.

It should be understood that the instrument panel is illustrative on onetrim panel and that both the method and product formed by the method ofthe present invention are equally suitable for use with other types oftrim panels. It should also be understood that the illustrated materialsare representative of the materials which can be used and are notintended to limit the invention. The shell may also be made in aseparate mold and later positioned in mold 40 for assembly with block 28and substrate 22.

Other variations and modifications are possible without departing fromthe scope and spirit of the present invention as defined by the appendedclaims.

The embodiments in which an exclusive property or privilege is claimedare defined as follows:
 1. A method of integrally molding a simulatedleather applique with a plastic panel of an interior trim component fora motor vehicle, said method characterized by the steps of:forming athin plastic outer shell having a back surface and front exposedsurface, said shell having a textured section; said thin plastic shellbeing positioned in a mold having a standing knife edge about thetextured section of said plastic shell; press fitting a cushion foamblock at the back surface of said shell on the textured section withside walls of said cushion foam block press fitted against a shellsection that abuts said standing knife edge; applying a moldable andcurable substrate on a back surface of said cushion foam block and theback surface of said plastic shell about the textured section; andcuring said substrate such that said substrate forms a rigid trim panelwith said cushion foam block and shell having a simulated appliquelocated in front of said cushion foam block at said textured section anda simulated seam where the knife edge of said mold was located aboutsaid textured section.
 2. A method as defined in claim 1 furthercharacterized by;said cushion foam block being non-porous or closedcell.
 3. A method as defined in claim 1 further characterized by;acompressible material being interposed between said cushion foam blockand said textured section during the press fitting of said cushion foamblock to allow deformation of said textured section upon an applicationof a small force after said substrate is cured.
 4. A method as definedin claim 3 further characterized by;said compressible material being apocket of air; said pocket of air being sealed against leakage by saidpress fitting of said block against said shell section that abuts saidknife edge.
 5. A method of integrally molding a simulated applique witha plastic panel of an interior trim component for a motor vehicle, saidmethod characterized by the steps of:forming a thin plastic outer shellhaving a back surface and front exposed surface, said shell having asimulated applique section having a texture distinctive from asurrounding area of said front exposed surface; positioning said thinplastic shell in a mold having a standing knife edge about the simulatedapplique section of said plastic shell; press fitting a non-porousmember at the back surface of said shell on the simulated appliquesection with side walls of said non-porous member fitted against a shellsection that abuts said standing knife edge; applying a moldable andcurable substrate on a back surface of said non-porous member and theback surface of said plastic shell about the simulated applique section;and curing said substrate such that it forms a rigid trim panel withsaid non-porous member and said shell with a simulated applique locatedin front of said non-porous member and a simulated seam where the knifeedge of said mold was located about said simulated applique section. 6.A method as define in claim 5 further characterized by;a pocket of airbeing interposed between said non-porous member and said simulatedapplique section during the press fitting of said non-porous member toallow deformation of said simulated applique section upon an applicationof a small force after said substrate is cured.
 7. A method ofintegrally molding a simulated deformable applique with a plastic panelof an interior trim component for a motor vehicle, said methodcharacterized by the steps of:forming a thin plastic outer shell havingan back surface and front surface, said shell having a simulatedapplique section having a texture distinctive from a surrounding area ofsaid front outer surface; positioning said thin plastic shell in a moldhaving a standing knife edge about the simulated applique section ofsaid plastic shell; fitting a member at the back surface of said shellbehind the simulated applique section such that an air pocket is formedbetween said simulated applique section of said shell and said memberwithin confines defined by a shell section that abuts said knife edge ofsaid mold; applying a moldable and curable substrate on said backsurface of said shell and on a back surface of said member wherein saidmember prevents said substrate from filling said air pocket curing saidsubstrate; and removing the mold such that a rigid trim panel is formedwith said shell with a simulated applique located in front of said airpocket and a simulated seam where the knife edge of said mold waslocated about said simulated applique section.